ISP-500B Oil-free Scroll Vacuum Pump Instruction Manual View our inventory Serial Number: Record of Pump Information Purchase date: In Service date: Dealer information: IM-500B 1/3/07 Page 1 of 26
Important Safety Information ISP-500B Be sure to read this manual to understand operation and functions correctly. Only operators, who fully understand warnings, cautions and instructions, are to operate the equipment. If not, fire, explosion, serious bodily injury or death may occur. About Safety Warnings and cautions are especially important for safe operation. Obey the safety instructions given below and take note of appropriate precautions. Marks and symbols have the following meanings. Examples of Marks Indicates a potentially hazardous situation which, if not avoided, may result in serious injury or loss of life. Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or property damage. Examples of Symbols Indicates you must be careful. We will explain briefly in or near the symbol. The example on the left is Be careful about electric shock Indicates [you must not do]. We will explain briefly in or near the symbol. (The example on the left is Do Not touch! Indicates an action you must do. We will explain briefly in or near the symbol. (The example on the left is Be sure to ground! * Neither the manufacturer nor the dealer from whom the pump was purchased shall be responsible for any injury or damage caused by disregard of warnings, cautions or instructions. Supplementary Notes Indicates notes which we ask you to observe. They are helpful to achieve full performance and function of the equipment. IM-500B 1/3/07 Page 2 of 26
Contents of Instruction Manual Important Information.....2 Contents... 3 1. For safe operation. 4 2. Specifications.. 7 3. Names of each section.. 9 4. Outer dimensions...10 5. Installation...11 6. Operation...18 7. Maintenance and inspection..24 8. Problems and remedies...26 IM-500B 1/3/07 Page 3 of 26
1.1 For safe operation As the below points are very important for safe operation, be sure to read and fully understand the contents before operation. Never pump toxic, explosive, flammable, corrosive gases, chemicals, solvents or powders. *Flowing substances, explosion or fire can cause bodily injury. Install in an area without explosive, flammable substances. *If not, it can cause explosion or fire. Install in an area which is not exposed to moisture such as rain or steam. *If not, it can cause electric shock. Be sure to cut off electric source before wiring or inspection. *If not, it can cause electric shock or damage by turning section (fan). Never put fingers or foreign matter into air hole of pump or clearance of cooling fins. *If done, it can cause injury. Ask qualified electrician to perform electric wiring job. *If not, electric shock may occur. Never alter the equipment. *If done, it can cause damage or shorter lifetime. Be sure to ground. *If not, it can cause electric shock or fire. Ask specialist to perform repairs. *If not, it can cause failure, damage or shorter lifetime. Prevent short-circuit with ground leakage breaker of proper capacity. *If not, it can cause electric shock or fire. Be sure to install electric source switch. *If not, it can cause damage or fire. IM-500B 1/3/07 Page 4 of 26
Be sure to check Wiring diagram before a power supply. (Refer to p. 13 and be shown inside terminal cover.) If not, it can cause damage. The pump has a motor thermal protector. Motor restart without warning after protector trip. Be sure to switch off electric source before maintenance or inspection. If not done, it can cause electric shock or bodily injury from turning objects. Install in a safe place. Install on a level foundation (an inclination of less than 5 ). in a place free of dirt or dust from iron, stone or wood. in a place free of corrosive gas. If done, it can cause damage, decrease in performance or shorter lifetime. Use at temperature of 5 ~ 40 C (during operation). *If not, it can cause damage or shorter lifetime. Do the maintenance after pump becomes fully cool. *If not, it can cause burns. Conduct periodic maintenance and inspections. *If not, it can cause damage or shorter lifetime. Be sure to close isolation valve between pump and vacuum system (chamber) during startup and stop. *If not, debris attached to inside of pump can be drawn back to vacuum chamber. IM-500B 1/3/07 Page 5 of 26
Where to attach warning stickers Always keep warning stickers clean. If they become dirty or lost, replace them with new ones. If you need stickers, contact the shop which sold the vacuum pump to you. ISP-500B Single Phase ISP-500B Three Phase IM-500B 1/3/07 Page 6 of 26
2.1 Specifications Displacement (swept volume) L/min 50 Hz 500 60 Hz 600 Ultimate pressure Pa (Torr) Leak tightness Pa (mbar) L/S Maximum inlet pressure Ambient operating temperature range <1 (<7.5 x 10-3 ) <1.0 x 10-2 (<1.0 x 10-4 ) Atmospheric pressure 5 C ~ 4 0 C Motor Type Single-phase induction motor 4P Totally Enclosed Insulation class BIP44 Capacitor start Thermal Protector TP212 Automatic Reset Type Output kw 0.6 3-phase induction motor 4P Totally enclosed Insulation Class B IP44 Voltage V 100 115 200 230 200 208 230 380 415 460 50Hz Rated current A Revolution min-1 (rpm) 60Hz 50Hz 60Hz 8.5-4.3 3.9 2.7 - - 1.57 1.63-10.0 8.6 4.8 4.0 2.8 2.6 2.5 - - 1.47 1430-1430 1450 1460 - - 1470 1470-1660 1720 1690 1730 1740 1740 1760 - - 1770 Note 1: Pumping speed and ultimate pressure remain the same when air flush is ON (opened) and OFF (closed). Note 2: Leak tightness is measured when pump is stopped and air flush is OFF (closed). Note 3: Water vapor handling is less than 25g/day (25 C humitidy 60%) when air flush is ON(opened). Air flush volume is 10 liters/min. Note 4: Air Flush is OFF (closed) when pump is delivered. IM-500B 1/3/07 Page 7 of 26
2.1 Specifications (continued) Noise level at 1m db(a) < 62 Single phase < 60 Three-phase with Air Flush ON (opened) < 70 < 68 Inlet connection NW 40 Outlet connection NW 25 Direction of inlet Laterally fitted (Perpendicularly fitted) Dimensions mm 443 x 328 x 372 372 x 328 x 372 L x W x H (443 x 298 x 397) (372 x 298 x 397) Mass kg 44 38 Cooling system Air cooled Air cooled Others Hour meter & Air Flush Hour meter & Air Flush Note 5: Noise level is measured at ultimate pressure in an anechoic room. Note 6: Three Phase Motor does not have over heat protection. Be sure to install a heat protection like a breaker. (Refer to p. 15) 2.2 Performance data IM-500B 1/3/07 Page 8 of 26
3.1 Names of each section IM-500B 1/3/07 Page 9 of 26
4.0 Outside Dimensions IM-500B 1/3/07 Page 10 of 26
5.0 Installation 5.1 Check the Product Check that the package is right-side-up and then open it. Check that model of the product is correct as you ordered. Check that there is no damage. If there is any damage, contact the vendor which sold it to you. Remove inlet blank flange and outlet blank flange. If you continue operation with blank flanges, it can cause damage. Check that air flush filter for air flush port is in the plastic bag. 5.2 Installation Danger of electric shock Install in an area which is not exposed to moisture such as rain or steam. Moisture on electric source connection can cause bodily injury by short circuit or electric shock. Danger of explosion and fire Install in an area which is not exposed to explosives, flammable gas, or other related things. If not, it can cause explosion or fire. IM-500B 1/3/07 Page 11 of 26
Operate at designated temperature. Operate at ambient temperature of 5 C ~ 40 C. Other temperature than designated ones can cause damage, burn Pay attention to ventilation. Install in a well-ventilated area (refer to right chart). Poor ventilation can cause abnormal overheating, burns or failure since it is air-cooled type. Necessary Ventilated Air ISP500B 8m 3 /min over 8m 3 /min Install in a safe place. Install in an area which is not exposed to dust or corrosive gas. If not, it can cause damage or failure. Install on a firm, level floor. Be sure to install on a firm, level floor (less than 5 inclination). Uneven installation can cause failure. If installation floor is unstable, fix pump base by using 4-M10 tap screws of pump base. Install in an area which is not exposed to sunshine. Direct sunshine can cause high temperature and failure. 5.3 Wiring Ask qualified electrician. Ask qualified electrician to perform electric wiring job. If not, electric shock or fire may occur. Turn off electric source. Be sure to turn off main electric source on building site. If not, it can cause injury due to electric shock. Check electric source and voltage. Check electric source and voltage before doing the wiring. There are single-phase and three-phase motors for ISP-500B. Three-phase has 200V/400V dual voltage. Single-phase has 100V/200V dual voltage. It is wired to 200V connection when delivered to you. Check electric source and voltage, and wiring. IM-500B 1/3/07 Page 12 of 26
How to Wire Remove terminal cover of motor and check terminal block inside. Wiring diagram is shown inside terminal cover. ISP-500B Single-phase You can change to 100V or 200V connection by changing terminal plate. It is wired to 200V connection when delivered to you. If you want to change to 100V connection, remove electric source terminal M4 nut and change terminal plate as illustrated below. Connect electric source cord through cable gland on the right side of terminal box. ISP-500B Three-phase You can change to 200V or 400V connection by changing terminal plate. It is wired to 200V when delivered to you. If you want to change to 400V connection, remove electric source terminal M4 nut and change terminal plate as illustrated. Connect electric source cord through cable gland on the bottom side of terminal box. Connect L1-L2-L3 to U1-V1-W1 terminals of motor, respectively. IM-500B 1/3/07 Page 13 of 26
Install emergency stop switch! Be sure to install electric source switch (or breaker for emergency stop) for emergency stop. If not, it can cause damage or fire. Only the single phase motor has a thermal protector! Single phase motor has a thermal protector with automatic reset function. Motor automatically restarts after protector trip when the motor gets cooler. When thermal protection works, be sure to switch off the power and inspect the abnormal conditions. (Refer to p. ) CSA REQUIREMENT With a thermal protector (single phase only) Three phase motor is NOT protected! External protection in accordance with CE Code, Part 1, MUST be provided. Minimum circuit ampacity of conductor is as follows: ISP-500B single phase 18A ISP-500B three phase 15A Maximum Branch Circuit Breaker is ISP-500B 15A (1 Phase 100/115V is 20A) Danger of fire due to electricity 1. Avoid motor burnout by installing recommended breaker. (refer to chart 1 on the next page) If not, it can cause bodily injury or fire due to electricity. 2. Use electric source cord and ground cord of over 2mm² (over rated 18A/single phase and 15A/three phase) for ISP-500B. If not, it can cause bodily injury or fire due to electricity. 3. Firmly fit proper round crimp-style terminal to electric cord with application device and connect to motor terminal. If not, it can cause bodily injury or electrical fire due to looseness or disconnection. 4. Be sure to connect electric cord to terminal by using cable gland at φ20mm hole of motor terminal box. If not, it can cause bodily injury or fire due to looseness or disconnection. 5. Be sure to ground. Connect ground cord to ground terminal in motor terminal box. If not, it can cause bodily injury such as electric shock. When Using This Pump In Europe This vacuum pump must be equipped with a main disconnect device in accordance with requirements of EN60204-1, clause 5.3.2. It is recommended to use a circuit breaker as main breaker which is suitable for isolation according to EN60947-2 and is equipped with an operating handle which is lockable in the OFF position and complies with the other requirements of EN60204-1, clause 5.3. IM-500B 1/3/07 Page 14 of 26
ISP-500B Three Phase with 200V connection Chart 1 Breaker Capacities for Single &Three-phase ISP-500B vacuum pumps V Single-phase specifications Hz Recommended Breaker Capacity A V Three-phase specifications Hz Recommended Breaker Capacity A 100 50 10.7 200 50 3.1 100 60 12.5 200 60 3.2 115 60 10.8 208 60 3.0 200 50 5.4 230 60 2.9 200 60 6.0 380 50 1.8 230 50 4.9 415 50 1.9 230 60 5.0 460 60 1.7 IM-500B 1/3/07 Page 15 of 26
Check turning direction after wiring Turning direction of pump is clockwise viewed form motor side. Operate pump with inlet opened, and check that air comes out from outlet. If it turns counterclockwise in case of three-phase, reverse any two phase wires in electric source connection. If you fit pump to vacuum system and switch pump ON-OFF with remote control, first check pump itself about turning direction and then fit it to vacuum system. Avoid dropping foreign matter inside. When checking turning directions, avoid dropping foreign matter into inlet. A drop of foreign matter can cause failure. IM-500B 1/3/07 Page 16 of 26
5.4 Connection to vacuum system Inlet of ISP-500B is NW40 and outlet is NW25. Use isolation valve (we recommend the use of leak valve also) between vacuum chamber and inlet (NW40 for ISP-500B). These valves (isolation valve and leak valve) are used to prevent the drawback of debris attached to the inside of vacuum pump into the vacuum chamber during start-up or shut-down. We recommend the use of automatic valve as isolation valve which closes during power failure in order to prevent the drawback of debris inside pump into the vacuum chamber during power failure. Use the clean connecting pipe between vacuum chamber and vacuum pump. We recommend the use of flexible pipe between inlet of pump and vacuum chamber so that vibration of pump does not transmit to vacuum chamber. IM-500B 1/3/07 Page 17 of 26
6.0 Operation Be sure to use the procedure below to start up or shut down the pump. If it takes time to reach ultimate pressure of pump during initial operation (also operation after pump has not been used for a long time) Close inlet, and continue operation for 6 8 hours while opening inlet for 3 ~ 5 seconds to atmosphere 2 3 times per hour. During pump stoppage, moisture might have entered inside of pump and decreased performance to reach ultimate pressure. If pump have pumped liquid such as water or high humid air (over 60% RH) during operation Moisture can deposit in pump and fail pump. Close isolation valve and open inlet for 3 ~ 5 seconds to atmosphere several times and exhaust moisture in pump to atmosphere. Remove blank flanges from inlet and outlet, and operate pump. Operation with blank flanges fitted can cause damage. Close isolation valve during start-up or shut-down of pump. Be sure to close isolation valve between vacuum pump and vacuum chamber during start-up or shut-down of pump. If not, debris attached to the inside of pump can be drawn back to vacuum chamber. Close isolation valve during start-up or shut-down of pump Precautions during restarting of pump Open inlet to atmosphere before restarting pump. If not, it can imbalance temperature in pump, resulting in failure. IM-500B 1/3/07 Page 18 of 26
6.1 Start-up 1. Close isolation valve in order to prevent the drawback of debris attached to the inside of vacuum pump into vacuum chamber. (Open leak valve when using leak valve). 2. Switch vacuum pump on. 3. Check start-up of vacuum pump and open isolation valve (close leak valve when using leak valve) and pump the vacuum chamber. Continuous pump operation at around ultimate pressure (for example, using as auxiliary pump of turbo molecular pump) can cause deposits of foreign matter or moisture in pump resulting in failure. Do the air flush operation, or close isolation valve and open inlet to atmosphere and operate (once a day for a few minutes) in order to remove foreign matter inside pump. Be careful not to damage air flush port (especially air flush filter). If not, it can cause damage or accident. During air flush operation (ON), noise level becomes a bit higher (by 7 8dB). Install pump in an area which is not exposed to debris such as iron, stone, polishing or wood dust. Debris can clog air mufflers, undercutting air flush effect. 6.2 Shut-down 1. In order to prevent the drawback of debris attached to inside of vacuum pump into vacuum during operation. Be sure to close isolation valve (open leak valve when using leak valve). 2. Switch vacuum pump off. 3. Open inlet of vacuum pump to atmosphere. When pump stops, atmospheric air is drawn back from air flush port to the inside of pump, and pressure inside pump becomes about atmospheric pressure. In order to maintain vacuum in vacuum chamber and prevent the drawback of debris from vacuum pump into vacuum chamber, be sure to close isolation valve to vacuum chamber and stop pump. When operating with air flush OFF (closed), operate as per 6.4. IM-500B 1/3/07 Page 19 of 26
Never pump hazardous gases. Do not pump hazardous gases to humans, or explosive, flammable, toxic or corrosive gases or substances which contain chemicals, solvents or powders. If done, it can cause bodily injury due to harmful substances, explosion or fire. DO NOT PUMP: Ø Ø Ø Ø Ø Ø Ø Ø Ø Toxic gas Explosive gas Flammable gas Corrosive gas Chemicals Solvents Powders Water Liquids Be careful about entanglement. Never put your fingers or foreign matter into wind holes of fan cover or motor set or clearance between cooling fans of FS(1) and FS(2). If done, it can cause bodily injury such as injury of fingers or foreign matter entering eyes. Never alter equipment. Never remove or alter safety equipment or insulation parts. If done, it can cause electric shock or bodily injury by turning objects. IM-500B 1/3/07 Page 20 of 26
6.3 Pumping vapor (Air Flush operation) This pump is equipped with air flush port. Before pumping vapor, fully read precautions below and understand the contents. Purpose of air flush Pumping of humid gas by vacuum pump can cause condensed moisture to remain in pump. This remaining moisture can cause failure to ultimate pressure to pump. Air flush operation is necessary to pump remaining moisture inside. Air flush operation does not only pump moisture but also recovers ultimate pressure. Maintenance standard of this pump is based on clean gas pumping. The standard differs when pumping vapor. You must shorten maintenance standard (7.1) when pumping vapor since vapor temperature, disposal volume, disposal frequency and substances in vapor have influence on pump operation. When pumping vapor, pay attention to the following points. 6.3.1 Operation and Shut-down 1. Start pump as per 6.1 2. Stop pump as per 6.2 Operate at designated temperature. When pumping vapor, inlet gas temperature must be less than 50 C. When vapor temperature is more than 50 C, install a chiller or trap in the piping between vacuum chamber and pump, in order to reduce inlet vapor temperature to less than 50 C. Pumping vapor of over 50 C can cause failure. Pump gas below 50 C temperature Operate with air flush port opened. When pumping vapor, be sure to open air flush port. (air flush operation) If you pump vapor with air flush port closed, condensed moisture remains in pump, resulting in failure. After vapor is pumped, continue air flush operation for over one hour. If you close air flush port or stop pump soon after vapor is pumped, condensed moisture remains in pump, resulting in failure. When supplying nitrogen gas or dry air to air flush port, set pressure equivalent to atmospheric pressure while keeping the flow less than 10 NL/min. If not done, higher pressure in pump can cause pump failure. Fit air flush filter IM-500B 1/3/07 Page 21 of 26
Continuous pumping of humid gas When pumping vacuum chamber while humidity in chamber is high, moisture volume drawn into pump differs according to temperature and pressure in chamber. When pumping chamber containing gas with humidity of over 60% RH be sure to open air flush port and operate pump. (air flush operation) Air Flush operation to pump humid gas 6.4 When finishing Air Flush operation. When you want to finish air flush operation, first stop pump and then do the following procedure. Never try to do during pump operation. Never change air flush condition ON-OFF during operation. Change air flush port condition (ON-OFF) after stopping pump. Changing air flush condition during operation can fail pump and cause bodily injury. Stop pump and then change! Position of Air Flush Port Air Flush Filter IM-500B 1/3/07 Page 22 of 26
6.4.1 Finish Air Flush operation To finish air flush operation, remove air flush filter of air flush port. Lightly tighten plug with spanner. Air Flush Filter (used during air flush operation) 6.4.2 Restart Air Flush operation To restart air flush operation, remove plug of air flush port and screw it into housing of air flush port. Stop pump before removing air flush filter, plug. IM-500B 1/3/07 Page 23 of 26
7.0 Maintenance and Inspection Neglect of maintenance and inspection can cause poor performance and pump failure. In order to remove debris accumulated in vacuum pump, operate pump several times for 3 ~ 5 seconds (once a day) while drawing atmospheric air. Observe maintenance and inspection Be careful about high temperature Do the maintenance after the pump becomes cool enough. Maintenance soon after shutdown of operation can cause bodily injury such as burns. Be careful of automatic restart Motor is thermally protected with automatic reset type for single phase motor. Motor automatically restarts after protector trip when the motor gets cooler. Be sure to switch off electric source before maintenance or inspection. When thermal protection works, be sure to switch off the power and inspect the abnormal conditions. (Refer to p.26) Be Careful of Automatic Restart! Switch off electric Source Be sure to switch off electric source before maintenance or inspection. If not done, it can cause bodily injury such as electric shock or injury from turning objects. IM-500B 1/3/07 Page 24 of 26
7.1 Maintenance When maintenance time has been reached, be sure to contact the vendor who sold it to you. Never disassemble, reassemble or alter on user s side. We are not responsible for any accidents caused by disassembly, assembly or alteration which was done by the user or non-specialist. Interval: Yearly or Interval: Biannually or Every 400 times Where to Inspect every 8000 hr. every 16,000 hr. vapor pumping Needle bearing [FS (2)] Grease / Δ Ο Δ Needle bearing [O S] Grease / Δ Ο Δ Ball bearing [F S (1)] Δ Ο Δ Needle bearing [Pin Crank] Grease / Δ Ο Δ O-ring [pin crank, Needle bearing] Δ Ο Δ Spider Δ Ο Δ Seal [pin crank Needle bearing] Ο Ο Δ Shaft seal (2) [F S (2)] Ο Ο Δ Shaft seal (1) [F S (1)] Ο Ο Δ G seal [F S (2)] Ο Ο Δ G seal [O S] Ο Ο Δ G seal [F S (1)] Ο Ο Δ Exhaust valve set Ο Ο Δ O-ring [F S (2)] Ο Ο Δ O-ring [Inlet flange] Ο Ο Δ Tip Seal set (1) Δ Ο Δ Tip Seal set (2) Δ Ο Δ Pin Crank set Δ Ο Δ Air Flush kit Ο Ο Ο Δ = Replace if something goes wrong Ο = Replace FS = Fixed Scroll O S = Orbiting Scroll Note 1: Be sure to use designated ISP exclusive grease. Note 2: The maintenance interval should be earlier one in either the period or running hours. Note 3: When you want further maintenance and inspection at the time of either 6 th year or 48,000 operating hours, please contact the distributor who sold the pump to you. Causes of Failure Shorten maintenance time if conditions of installation or operation are bad. Especially ambient temperature has great influence on failure. Maintenance time is based on 5-40 C ambient temperature and 25 C average yearly temperature. Shorten maintenance time if temperature is over it. If not, it can cause failure. Maintenance time is not a guarantee time. Shorten Maintenance Time IM-500B 1/3/07 Page 25 of 26
8.0 Problems and Remedies If something goes wrong, please refer to the following chart and remedy problems. If you cannot solve your problem, please contact the vendor who sold the pump to you. Problems Causes Remedies Pump does not rotate Ultimate pressure is Insufficient Abnormal sound, vibration Breaker malfunctions Wiring becomes loose or cut. Voltage drops Motor malfunctions Pump malfunctions Thermal protector trips Air leaks from piping Moisture and solvent are drawn. O Ring is damaged Air Flush port is clogged Connection becomes loose The set is not level. Foreign matter enters inside of pump Failure of exhaust valve Failure of motor Failure of pump Inspect and repair. Repair or replace. Check length and size of cable Inspect and repair. Inspect and repair. Inspect connection in thermal box Inspect wiring Inspect voltage Inspect and repair Check tightness of piping Open inlet to atmosphere and operate for a few minutes and then operate for a time (about 24 hours) while inlet is closed. Install a trap or a filter to prevent the water and solvent from pumping. Replace Clean air flush filter. Replace. Tighten connection. Make it level. Inspect and repair. Inspect and repair. Inspect and repair. Inspect and repair. = Contact the distributor who sold the pump to you. IM-500B 1/3/07 Page 26 of 26